Front Shock (and spring) Instructions.

• Front Damper Removal
• Front Damper Disassembly/Inspection
• Front Damper Reassembly
• Front Damper Installation
• Front Suspension Torque settings.

Front Damper Removal

	1. Remove the brake hose clamps from the damper.
	2. Remove the damper pinch bolt.
	3. Remove the damper fork bolt* and remove the damper fork.
	4. Remove the damper by removing the two 10 mm nuts.

*The Helm manual tells you to replace the "self-locking nut" that you have removed from the damper fork bolt.


Top


Front Damper Disassembly/Inspection

	1. Compress the damper spring with the spring compressor according 	   
	   to the manufacturer's instructions, then remove the self-locking nut*.
CAUTION: Do not compress the spring more than necessary to remove the nut.

	2. Remove the spring compressor then disassemble the damper as 	 	    
	   shown on the next page.  (Note: The next page simply shows an 
	   exploded diagram. No actual "instructions" are present.) 
	3. Check for smooth operation through a full stroke, both compression
	   and extension.
	4. Also check for smooth operation in short strokes of 5 - 10 cm 
	   (2-4 in). Replace the damper if resistance is uneven or jerky.
	5. Check for oil leeks, abnormal noises or binding during these 
	   tests.
*The Helm manual tells you to replace the "self-locking nut" that you have removed from the damper.


Top



Front Damper Reassembly

	1. Install the damper unit, damper spring, bump stop, boot, upper 
	    spring seat, damper bushings and collar on the spring compressor.
	2. Mark the damper at 2 points by measuring around from the 
	    damper fork aligning tabs. Align the two points with the stud bolts 
	    on the mounting base.
	NOTE: Some damper units will have a projection at one of the 
	alignment points.
	3. Compress the damper spring.
	4. Install the damper mount washer and the new 10mm self-locking 
	    nut.
	5. Hold the damper shaft and tighten the 10mm self-locking nut.


Top



Front Damper Installation

	1. Loosely install the damper on the frame with the aligning tab 
	   facing inside.
	2. Install the damper fork on the driveshaft and lower arm. Install the 
	    damper in the damper fork so the aligning tab is aligned with the 
	    slot in the damper fork. Hand tighten the bolts and nuts.
	3. Raise the knuckle with a floor jack until the car just lifts off the 
	    safety stand.
	4. Tighten the damper pinch bolt.
	5. Secure the damper fork bolt with a new 12mm self-locking nut.
	6. Install the brake hose clamps with the two bolts.
	7. Secure the damper assembly to the frame with the 10mm locking 
	    nuts.

• Damper spring 10mm self-locking nut = 31 N-m (3.1 kg-m, 22 lb-ft)
• 10mm Damper, top mounting bolts (2) = 40 N-m (4.0 kg-m, 29 lb-ft)
• Brake hose clamp bolts (2) = 10 N-m (1.0 kg-m, 7 lb-ft)
• Pinch Fork Bolt = 44 N-m (4.4 kg-m, 32 lb-ft)
• The Damper Fork Bolt's self-locking nut = 65 N-m (6.5 kg-m, 47 lb-ft)

Top						Return to main Helm Instructions.